Automotive Crankcase Ventilation System Market By System Type (Open Crankcase Ventilation, Closed Crankcase Ventilation); By Vehicle Type (Passenger Vehicles, Commercial Vehicles, Off-Highway Vehicles); By Component (Oil Separators, Pressure Control Valves, Hoses/Filters/Gaskets); By Geography, Segment Revenue Estimation, Forecast, 2024–2030

1. Introduction and Strategic Context

The Global Automotive Crankcase Ventilation System Market is projected to grow at a steady pace, moving from an estimated USD 3.1 billion in 2024 to around USD 4.7 billion by 2030 , expanding at a CAGR of 7.1% during the forecast period, according to internal estimates.

Crankcase ventilation systems might not grab headlines like EV batteries or ADAS platforms, but they serve a critical function in keeping modern engines compliant, clean, and efficient. At their core, these systems capture and redirect harmful blow-by gases from the crankcase back into the intake manifold — preventing oil contamination, reducing emissions, and ensuring engine longevity. That said, their strategic importance is rising, especially as OEMs tighten their grip on emissions targets in internal combustion engines (ICE) and hybrid vehicles.

From a regulatory standpoint, emissions norms like Euro 7, China 6b, and the U.S. EPA Tier 3 are pushing automakers to squeeze every last gram of unburned hydrocarbons from their powertrains. Crankcase emissions — once overlooked — are now under the microscope. That’s driving adoption of closed-loop systems with oil separators, PCV valves, and active pressure control.

Electrification isn’t sidelining this market either. Plug-in hybrids, mild hybrids, and range-extender EVs still rely on combustion engines — and these engines must meet the same emissions benchmarks as their ICE-only counterparts. In fact, many hybrid platforms feature start-stop cycling and turbocharged engines, both of which increase blow-by pressure and oil mist, raising the stakes for efficient crankcase management.

This market sits at the intersection of compliance, performance, and engine health. It’s not just Tier 1 suppliers who are doubling down — but also filtration specialists, materials vendors, and OEM engine development teams. Stakeholders range from engine system integrators and automotive OEMs to aftermarket players , emission control regulators , and investment funds focused on green ICE technologies .

2. Market Segmentation and Forecast Scope

The automotive crankcase ventilation system market divides cleanly across four core dimensions: system type , vehicle type , component , and region . Each reflects a different set of performance pressures — from regulatory compliance to thermal load and design constraints.

By System Type

Open Crankcase Ventilation (OCV) Systems These are traditional setups where blow-by gases are vented into the atmosphere or intake stream with minimal filtration. OCVs are still found in older vehicle models and cost-sensitive commercial fleets. That said, regulatory pressure is making them obsolete fast — especially in Europe and North America.

Closed Crankcase Ventilation (CCV) Systems These are now the industry standard, especially in turbocharged and hybrid engines. CCV systems redirect blow-by gases back into the intake, paired with oil separators and valves to prevent oil mist contamination. In 2024, closed systems account for nearly 68% of the market , a share that’s growing each year.

CCV’s dominance isn’t just about emissions — it’s about engine durability, especially in high-boost, downsized engines.

By Vehicle Type

Passenger Vehicles The largest and most rapidly evolving segment. OEMs are integrating compact, lightweight crankcase ventilation modules directly into valve covers or cylinder heads. European automakers, in particular, are leading with modular PCV-integrated cylinder head covers.

Commercial Vehicles Used in medium-duty and heavy-duty fleets, this segment often opts for high-capacity oil separators with serviceable filters. Many commercial platforms still run diesel engines, where crankcase emissions are higher — driving demand for more robust, high-flow systems.

Off-Highway Vehicles (Ag, Construction, Rail ) An often overlooked but steady slice of the market. Equipment like tractors and excavators runs at high load for long durations — making them prone to higher crankcase pressures and requiring heavy-duty CCV solutions.

By Component

Oil Separators These remove oil mist from blow-by gases before recirculation. They come in cyclonic, baffle, or coalescing formats and can be active or passive. Many Tier 1 suppliers are now offering multi-stage separators with integrated pressure control.

Pressure Control Valves (PCV Valves ) A critical component that modulates crankcase pressure and ensures optimal gas routing under various load conditions. Electrically actuated PCV valves are now entering high-performance and hybrid applications.

Hoses, Filters, and Gaskets While commoditized, these parts are vital for system integrity — especially under heat cycling and vibration. Material upgrades here (e.g., FKM seals) are increasing to withstand longer lifecycles.

By Region

North America and Europe lead in adoption of CCV technologies, thanks to early regulatory enforcement and widespread use of turbocharged engines. Meanwhile, Asia Pacific , led by China and India, is growing the fastest due to increased vehicle production and new emissions mandates.

OEMs in these regions are beginning to localize CCV module sourcing — a shift from global to regional supplier alignment.

3. Market Trends and Innovation Landscape

This market may seem mature, but under the hood, it’s changing fast. Crankcase ventilation systems are evolving in tandem with modern engines — smaller, hotter, higher-boosted, and more hybridized. Here’s what’s pushing the innovation cycle forward:

Thermal and Pressure Complexity in Modern Engines

New-gen turbocharged and downsized engines operate under higher crankcase pressures and thermal loads. That’s forcing system redesigns — from single-stage oil separators to multi-stage cyclone-coalescing hybrids . These upgraded separators reduce oil mist and pressure spikes, especially during engine braking and high-load acceleration.

Also, integrated thermal management is a growing focus. Some OEMs are now designing coolant-assisted oil separators to prevent condensation and emulsification, particularly in cold-start cycles — a known pain point for hybrid vehicles.

Shift Toward Electrically Actuated PCV Valves

Traditional PCV valves rely on vacuum or spring-loaded mechanics. But that’s less effective in engines with start-stop functionality or dynamic boost levels. The emerging solution? Electronically controlled PCV valves .

These valves adjust ventilation flow in real-time, responding to sensor data on crankcase pressure, throttle position, and boost load. OEMs see this as key for managing blow-by in high-efficiency ICEs and PHEVs, especially where combustion cycles are unpredictable.

Integrated Ventilation Modules (IVMs) Are Gaining Ground

Instead of installing ventilation components individually — separator, valve, sensor — several Tier 1s now offer fully integrated ventilation modules . These compact assemblies mount directly onto the cylinder head or valve cover, simplifying assembly and improving sealing.

One German automaker recently adopted IVMs for its new inline-4 hybrid platform — citing 30% space savings and better oil capture during start-stop cycles.

Advanced Materials for Oil Separation and Durability

Materials innovation is quietly transforming reliability. New filters made from nonwoven synthetic mesh or plasma-coated cyclonic inserts are improving oil separation efficiency by over 90% — even in high-shear applications. Some suppliers are now developing self-cleaning separator mesh to reduce maintenance in long-haul commercial vehicles.

Meanwhile, pressure valves are shifting to high-temperature fluoropolymer blends , especially in diesel platforms, to handle soot contamination and hot gas cycling.

Onboard Diagnostics and Sensorization

There’s a growing push to sensorize crankcase systems , particularly in fleet and commercial vehicles. Sensors for pressure, oil mist density, and valve position allow predictive maintenance — a key feature for fleets aiming to reduce unplanned downtime.

Expect these diagnostics to be increasingly linked to vehicle OBD-II platforms and fleet telematics systems.

Tailored Designs for Hybrid and Start-Stop Platforms

Hybrids pose a unique challenge. Their ICEs start and stop frequently, creating irregular pressure cycles and condensation risk. To counter this, some platforms now feature active CCV systems with warm-up logic and delayed recirculation — avoiding oil dilution during cold starts.

Start-stop systems, especially in urban vehicles, also benefit from low-volume, fast-reacting separators that engage almost instantly when combustion resumes.

4. Competitive Intelligence and Benchmarking

The automotive crankcase ventilation system market might seem like a niche component space, but the competitive playbook here is anything but basic. Suppliers that succeed are those who understand both the regulatory heat and the engineering nuance — and respond with smart, scalable solutions.

MAHLE GmbH

A clear leader in this space, MAHLE has built a strong position through its Integrated Oil Mist Separator (IOMS) platforms and modular closed crankcase systems. They serve both passenger and commercial vehicle OEMs globally and often customize CCV modules for specific engine architectures. Their edge lies in combining deep engine know-how with filtration science.

They’ve also partnered with several OEMs on active crankcase pressure control systems , especially for Euro 7-compliant engines in Europe and India.

MANN+HUMMEL

Known for their filtration expertise, MANN+HUMMEL offers a wide range of oil separators and blow-by filters . What sets them apart is material innovation — like multi-layered coalescing media and cyclonic separator technology. They’ve also pushed early into digital sensors for crankcase pressure monitoring.

Their passive and active systems are widely used in premium ICE platforms and light-duty commercial vehicles. They’re also expanding into electric auxiliary ventilation for range-extender hybrids.

Rheinmetall Automotive (formerly KSPG)

A strong European player, Rheinmetall focuses on integrated mechatronic solutions for pressure regulation and oil separation. Their electric PCV valve systems are among the most advanced — designed specifically for turbocharged and start-stop engines.

They’ve also filed patents around adaptive ventilation control , which changes separator behavior based on driving style and ambient temperature — giving them a strategic edge in emission-sensitive markets.

Seg Automotive

Initially spun off from Bosch, SEG Automotive is gaining traction in hybrid platforms. They don’t compete broadly across all crankcase components, but they specialize in pressure sensing modules and miniaturized electromechanical valves for ventilation control. Their work is aligned closely with OEMs moving toward electrified ICE architectures.

They recently introduced a low-voltage active pressure regulator optimized for 48V hybrid systems — giving them an early lead in that emerging spec niche.

Donaldson Company

While better known for commercial filtration, Donaldson plays a strong role in heavy-duty diesel crankcase systems . Their High-Efficiency Coalescing (HEC) filters are standard in many North American and Asian truck platforms.

Their value proposition? Ruggedness. They prioritize field-serviceable filters and long change intervals, which appeals to fleet operators. Their dominance is most visible in North American Class 8 trucks and off-highway machinery.

Cummins Filtration ( Fleetguard )

A trusted supplier in the commercial engine segment, Fleetguard offers complete CCV systems tailored for Cummins and other OEM diesel engines. Their EnviroGuard system is widely used for emissions-compliant crankcase filtration, offering high flow and long service life.

They’re now piloting AI-linked condition monitoring for crankcase filters in fleet vehicles — allowing predictive maintenance scheduling, especially in high-mileage applications.

Competitive Snapshot :

• MAHLE and MANN+HUMMEL dominate in the passenger car segment with broad modular offerings.
• Donaldson and Fleetguard control the commercial and off-highway verticals.
• Rheinmetall and SEG Automotive are pushing into intelligent, sensor-based systems — especially for hybrid ICEs.

Truth is, there’s no single market leader across all segments. Instead, what wins is alignment — between system design, emissions mandates, and the evolving shape of ICE platforms.

5. Regional Landscape and Adoption Outlook

Regional trends in the crankcase ventilation system market are defined by one thing: emissions pressure. The pace of adoption and level of system sophistication vary sharply based on how tightly a country regulates blow-by emissions — and how quickly its OEMs are transitioning to hybrid powertrains.

North America

This is a mature, high-regulation market — especially in the U.S., where the EPA has enforced crankcase emission controls since the early 2000s. As a result, closed crankcase ventilation (CCV) systems are now standard across all new vehicles, from pickup trucks to Class 8 freight haulers.

Most U.S. OEMs prefer modular systems — often integrated into the valve cover to reduce complexity. In the commercial segment, fleet operators demand long-life filters and diagnostics-ready CCV systems that tie into telematics platforms. Canadian and Mexican regulations generally align with U.S. standards, driving uniform demand across NAFTA countries.

Interestingly, the push toward hybrid pickups and light-duty commercial EVs is still keeping CCV demand stable, since most models still include combustion engines.

Europe

This is arguably the most innovation-driven region for crankcase systems. The upcoming Euro 7 standards are forcing OEMs to rethink the entire blow-by management architecture — especially in turbocharged and downsized engines.

German, French, and Scandinavian automakers are spearheading sensor-integrated, thermally managed CCV modules . The region also leads in electrified PCV valves , particularly for plug-in hybrid and mild-hybrid setups.

Eastern Europe, while following Euro norms, still relies on legacy OCV systems in low-cost platforms. That’s likely to shift as local production hubs upgrade to export-ready powertrain configurations.

Asia Pacific

Asia Pacific is the fastest-growing region in terms of volume, led by China, India, Japan, and South Korea . China’s China 6b emission norm mirrors Euro 6, and upcoming regulations are already pushing closed crankcase systems into mainstream production .

Indian OEMs, responding to BS VI Stage 2 , are rapidly phasing out OCVs in favor of compact cyclone-based CCV systems . The challenge in India is cost — so most solutions prioritize simplicity and serviceability.

Japan and South Korea lead in hybrid-optimized crankcase modules. Toyota and Hyundai, in particular, are adopting warm-up-controlled separators and hybrid-friendly PCV valves to manage intermittent ICE use.

Southeast Asia remains a mixed bag. Thailand and Indonesia are slowly aligning with global standards, but OCVs still dominate in two-wheelers and low-cost utility vehicles.

Latin America, Middle East & Africa (LAMEA)

This region trails in adoption, mostly due to less stringent regulation and slower hybrid penetration. In Brazil and Argentina , closed systems are only required on certain vehicle classes. However, local subsidiaries of global OEMs are introducing Euro 6-compliant engines with CCV as standard — particularly in export-focused models.

The Middle East sees moderate adoption, particularly in diesel-heavy commercial fleets where oil control and engine longevity are priorities due to high heat. African nations remain largely untapped — a few pilot programs involving aftermarket CCV retrofits are emerging, but volumes remain low.

Regional Outlook at a Glance :

• Europe and North America are tech leaders, driven by emissions compliance and hybrid integration.
• Asia Pacific is the volume driver, with China and India setting the pace.
• LAMEA offers long-term potential, but only as emission mandates tighten.

6. End-User Dynamics and Use Case

When it comes to crankcase ventilation systems, end users aren’t just automakers. This market runs deep into engine builders, fleet operators, commercial vehicle upfitters , and even aftermarket installers . Each brings a different set of expectations around cost, durability, and compliance.

Automotive OEMs

This is the largest end-user segment. OEMs across Europe, North America, and Asia are now treating crankcase ventilation systems as an integral emissions control subsystem , rather than an accessory. In most passenger car platforms, CCV modules are integrated directly into the valve cover or cylinder head , helping save space, reduce leak points, and simplify engine assembly.

What matters most for OEMs?

• Compact design with multi-function integration (oil separation, pressure control, sensors)
• Regulatory compliance (Euro 7, EPA Tier 3, China 6b)
• Compatibility with start-stop and hybrid engines

OEMs aren’t looking for cheaper parts — they want supplier partners who can co-develop modular, emissions-ready systems.

Commercial Vehicle Fleets

Fleet operators — especially in logistics, agriculture, and mining — demand robust and serviceable crankcase systems . Unlike passenger cars, these vehicles run long hours, under heavy load, often in dusty or hot environments.

Top priorities:

• High-flow, high-efficiency oil separators
• Field-replaceable filters
• Diagnostics for predictive maintenance

In North America, for instance, many Class 8 trucks use Donaldson or Fleetguard CCV units with built-in sensors that connect to fleet telematics — helping prevent unplanned engine downtime due to crankcase overpressure.

Engine Remanufacturers and Tier-2 System Integrators

In emerging markets like India, Indonesia, and Brazil, independent engine builders still play a major role. They assemble or recondition engines for utility vehicles, gensets , or small trucks — and often install aftermarket CCV systems to meet newer emissions norms.

These users prioritize:

• Simple installation and hose routing
• Mechanical reliability (no electronics)
• Cost-effective compliance (especially for export)

Many rely on local filtration brands or adapt solutions from passenger cars into commercial diesel platforms — creating a hybridized demand for versatile component sets.

Aftermarket and Retrofit Installers

This niche is gaining relevance in Latin America, Africa, and parts of Southeast Asia, where government incentives are pushing retrofitting of CCV systems on older diesel vehicles. The goals: reduce visible emissions, extend engine life, and meet inspection standards.

A growing number of regional workshops now offer crankcase retrofit kits , especially for light-duty pickups and utility vans. Though volumes are low, this channel is expected to scale as environmental audits expand to older fleets.

Use Case Highlight

A regional logistics fleet in Texas operating 150 heavy-duty diesel trucks faced rising maintenance costs due to oil contamination and crankcase pressure faults. They replaced legacy OCV setups with closed-loop Donaldson CCV systems featuring replaceable filters and pressure sensors.

After one year:

• Oil consumption dropped 25%
• Service intervals increased by 30%
• Emission-related engine codes declined sharply

Drivers reported fewer breakdowns, and the fleet used the sensor data to build preventive maintenance schedules . The investment paid off within nine months — not from emissions savings alone, but from better engine uptime .

7. Recent Developments + Opportunities & Restraints

Recent Developments (2023–2025)

• MAHLE unveiled its next-generation multi-stage oil separator in late 2023, optimized for Euro 7 readiness. It includes integrated sensors for pressure and oil mist levels, with a focus on small turbocharged engines.
• Rheinmetall Automotive announced a patent in 2024 for an electronic PCV valve with adaptive flow control based on engine load and ambient temperature — particularly suited for hybrid ICE systems.
• Donaldson Company rolled out an AI-assisted diagnostic platform in 2024 that links CCV filter condition data directly to fleet management software. This is already being piloted in over 5,000 commercial vehicles across the U.S.
• In early 2025, MANN+HUMMEL launched a compact closed-loop separator for low-displacement engines targeting emerging markets. It combines a coalescing mesh with vibration-resistant sealing for off-road applications.
• Fleetguard (Cummins Filtration) introduced a service-free CCV module with a 1-million-mile lifecycle warranty for long-haul diesel trucks. It’s now in field trials in North America and Europe.

Opportunities

• Hybrid ICE Optimization Start-stop and plug-in hybrid powertrains need advanced crankcase systems that manage irregular pressure cycles and cold-start condensation. Suppliers offering fast-reacting separators and intelligent valves have a clear runway for growth.
• Asia Pacific Emissions Convergence As China and India tighten emission standards, there’s a window for mid-tier CCV suppliers to scale in volume-driven segments. OEMs there seek solutions that balance regulatory compliance with cost — especially in compact cars and mid-range diesel trucks.
• Sensorized Aftermarket Kits Retrofitting demand is quietly growing in Latin America and Southeast Asia , particularly for fleets and inspection-compliant diesel engines. Modular sensor-ready kits with pressure alerts could be a breakout product line for aftermarket players.

Restraints

• Low Cost Pressure in Emerging Markets While compliance is rising, margins are thin. Many regional OEMs still resist adding CCV modules that increase BOM cost. Unless local mandates tighten, open crankcase systems may persist , especially in entry-level vehicles.
• Integration Complexity with Hybrid Engines Crankcase systems must now work across varying engine duty cycles. Designing components that don’t over-condensate or under-separate in hybrid cycles is difficult — especially without direct collaboration with OEM engine teams.

7.1. Report Coverage Table